Interchangeable Battery Switch Plugs for Safe Voltage Reconfiguration
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Solution Overview
Problem
Batteries for high power systems face challenges in switching between different voltage levels due to complex circuitry requirements and risks of electrical arcing, which can damage connected systems and pose fire hazards from over-discharged batteries.
Innovation Solution
A switch assembly for a battery module that allows secure switching between voltage levels using a base unit with interchangeable plugs, each plug having specific connectors to connect contacts in parallel or series configurations, preventing accidental damage and overcharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional circuits are used to change voltage levels of a battery, then voltage switching is achieved, but the circuitry becomes complex and electrical arcing occurs reducing battery lifetime
Solution Approach 1:
The battery system is segmented into multiple battery modules (first battery module and second battery module) that can be independently connected to different voltage terminals. This segmentation allows voltage level switching by selectively connecting modules in series or parallel configurations without requiring complex internal circuitry within each module.
Solution Approach 2:
A controller acts as an intermediary between the battery modules and the load, managing the connection and disconnection of modules to achieve different voltage levels. The controller coordinates the switching operations to prevent electrical arcing and ensure safe transitions between voltage configurations.
2Adaptability or versatility
If conventional circuits are used to change voltage levels of a battery, then voltage switching is achieved, but electrical arcing occurs causing damage to connected systems
Solution Approach 1:
The system performs preliminary actions by pre-configuring multiple battery modules in ready states and using the controller to manage switching sequences. This allows voltage level changes to occur in a controlled manner that prevents electrical arcing and protects connected systems from damage.
3Power
If lithium-ion batteries are used for high power systems, then high power performance is achieved, but fire risks are increased due to over-discharged batteries
Solution Approach 1:
The controller continuously monitors the state of charge of each battery module and provides feedback to manage charging and discharging operations. This feedback mechanism prevents any single module from becoming severely over-discharged, thereby eliminating the root cause of lithium-ion battery fires while maintaining high power system performance.
Data Source
AI summary
A switch assembly for a battery module comprises a base unit, a first plug, and a second plug. The base unit defines a socket in which are located first and second positive contacts and first and second negative contacts. The first plug is configured to be inserted into the socket and comprises a first connector operable to connect the first positive contact to the second positive contact and a second connector operable to connect the first negative contact to the second negative contact when the first plug is inserted into the socket. The second plug comprises a connector operable to connect only the first positive contact to the second negative contact when the second plug is inserted into the socket.